Torque bar and methods for making

ABSTRACT

A torque bar manufactured by an additive manufacturing process is provided. The torque bar may include a torque bar body made of more than one metallic material. The torque bar may also include a geometry that comprises one or more voids and one or more webs, as well as a varied geometry in the direction of a longitudinal axis. The torque bars can exhibit characteristics, such as vibration damping, tuned stiffness, and tuned bending resistance in order to enhance dynamic stability.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of, claims priority to and the benefitof, U.S. Ser. No. 14/264,380 filed Apr. 29, 2014 and entitled “TORQUEBAR AND METHODS FOR MAKING,” which is incorporated herein in itsentirety for all purposes.

FIELD

The present disclosure relates to components of wheel and brakeassemblies, and more specifically, to torque bars made using additivemanufacturing.

BACKGROUND

Torque bars are typically used in aircraft wheel and brake assemblies tocouple the wheels to the rotors of the brake assembly. Torque barstypically extend from an inner surface of the wheel in a directionparallel to the rotational axis of the wheel, and are subject todeflection and vibration.

The geometries of torque bars of the prior art are limited byconventional manufacturing techniques, such as subtractive manufacturingtechniques. These geometric limitations can in turn limit thecharacteristics of the torque bars, such as, for example, their abilityto resist deflection and dampen vibration. As such, the need exists fortorque bars with improved geometries and configurations.

SUMMARY

An exemplary torque bar is manufactured using an additive manufacturingprocess. The torque bar may comprise a torque bar body having a mountinghole and a pin. In various embodiments, the torque bar body comprises afirst perpendicular cross sectional profile and a second perpendicularcross sectional profile that are different from each other. The shape ofthe torque bar body can be configured to provide stiffness to the torquebar body. Further, the torque bar can comprise one or more voids.

A method for manufacturing a torque bar by an additive manufacturingprocess may comprise defining a torque bar design having a torque barbody, a mounting hole located in the torque bar body, and a couplingdevice, and manufacturing a torque bar based to be used in a subsequentcasting process. In various embodiments, the step of defining a torquebar design comprises utilizing a two-dimensional modeling technique. Thestep of manufacturing the torque bar can further comprise the sub-stepsof creating a prototype torque bar or prototype torque bar investmentbased on the torque bar design using an additive manufacturing process,and manufacturing a torque bar based on the prototype torque bar orprototype torque bar investment using a casting process.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter of the present disclosure is particularly pointed outand distinctly claimed in the concluding portion of the specification. Amore complete understanding of the present disclosure, however, may bestbe obtained by referring to the detailed description and claims whenconsidered in connection with the drawing figures, wherein like numeralsdenote like elements.

FIG. 1 illustrates a perspective view of a prior art wheel and brakehousing;

FIG. 2 illustrates a perspective view of a prior art wheel and brakehousing;

FIGS. 3A and 3B illustrate a perspective view and a top view,respectively, of a prior art torque bar;

FIG. 4 illustrates a top view of a torque bar, in accordance withvarious embodiments;

FIG. 5A illustrates a cross sectional view of the torque bar of FIG. 4as viewed from the line A-A.

FIG. 5B illustrates a cross sectional views of the torque bar of FIG. 4as viewed from the line B-B.

FIG. 6 is a process flow diagram for manufacturing a torque bar withadditive manufacturing, in accordance with various embodiments; and

FIG. 7 is another process flow diagram for manufacturing a torque bar inaccordance with various embodiments.

DETAILED DESCRIPTION

The detailed description of exemplary embodiments herein makes referenceto the accompanying drawings, which show exemplary embodiments by way ofillustration. While these exemplary embodiments are described insufficient detail to enable those skilled in the art to practice theinventions, it should be understood that other embodiments may berealized and that logical changes and adaptations in design andconstruction may be made in accordance with this invention and theteachings herein. Thus, the detailed description herein is presented forpurposes of illustration only and not of limitation. The scope of theinvention is defined by the appended claims. For example, the stepsrecited in any of the method or process descriptions may be executed inany order and are not necessarily limited to the order presented.Furthermore, any reference to singular includes plural embodiments, andany reference to more than one component or step may include a singularembodiment or step. Also, any reference to attached, fixed, connected orthe like may include permanent, removable, temporary, partial, fulland/or any other possible attachment option. Additionally, any referenceto without contact (or similar phrases) may also include reduced contactor minimal contact.

Furthermore, any reference to singular includes plural embodiments, andany reference to more than one component or step may include a singularembodiment or step. Surface shading lines may be used throughout thefigures to denote different parts but not necessarily to denote the sameor different materials.

As used herein, the term “additive manufacturing” encompasses any methodor process whereby a three-dimensional object is produced by creation ofa substrate or material to an object, such as by addition of successivelayers of a material to an object to produce a manufactured producthaving an increased mass or bulk at the end of the additivemanufacturing process than the beginning of the process. In contrast,traditional manufacturing (e.g., forms of subtractive manufacturing) bymachining or tooling typically relies on material removal or subtractiveprocesses, such as cutting, lathing, drilling, grinding, and/or thelike, to produce a final manufactured object that has a decreased massor bulk relative to the starting workpiece. Other traditionalmanufacturing methods includes forging or casting, such as investmentcasting, which utilizes the steps of creating a form, making a mold ofthe form, and casting or forging a material (such as metal) using themold. As used herein, the term “additive manufacturing” should not beconstrued to encompass fabrication or joining of previously formedobjects.

A variety of additive manufacturing technologies are commerciallyavailable. Such technologies include, for example, fused depositionmodeling, polyjet 3D printing, electron beam freeform fabrication,direct metal laser sintering, electron-beam melting, selective lasermelting, selective heat sintering, selective laser sintering,stereolithography, multiphoton photopolymerization, and digital lightprocessing. These technologies may use a variety of materials assubstrates for an additive manufacturing process, including variousplastics and polymers, metals and metal alloys, ceramic materials, metalclays, organic materials, and the like. Any method of additivemanufacturing and associated compatible materials, whether presentlyavailable or yet to be developed, are intended to be included within thescope of the present disclosure.

In various embodiments and with reference to FIGS. 1 and 2, a wheel andbrake assembly 100 can comprise a wheel 102 having a radially innersurface 104. A brake assembly 106 is disposed within wheel 102. Invarious embodiments, a plurality of torque bars 110 are orientedparallel to an axis of rotation 112 and coupled to wheel 102 andradially inner surface 104, and configured to engage with brake assembly106.

In various embodiments and with reference to FIGS. 3A and 3B, a torquebar 110 of the prior art is illustrated. Torque bar 110 comprises atorque bar body 320. Torque bar 110 further comprises a mounting hole322. Mounting hole 322 can be configured to couple to radially innersurface 104. For example, as illustrated in FIG. 1, a bolt can be passedthrough a bolt hole 130 in radially inner surface 104 and into mountinghole 322.

Torque bar 110 can further comprise a pin 324. In various embodiments,pin 324 is configured to couple torque bar 110 to wheel 102. Forexample, as illustrated in FIG. 1, wheel 102 can comprise a pinreceptacle 132 configured to receive pin 324. In various embodiments,pin receptacle 132 can comprise a pin or stud over which a hole in theend of pin 324 slides or engages. However, any manner of coupling torquebar 110 with wheel 102 is within the scope of the present disclosure.

Typically, torque bars of the prior art comprise a metal material, suchas steel or nickel base superalloys, which is cast into the desiredshape of the torque bar through traditional manufacturing methods, suchas casting or subtractive manufacturing. Such techniques tend to limitthe potential geometries and configurations of the resulting torque barsin that torque bars produced in this manner are prone to vibrationduring braking.

In various embodiments and with reference to FIG. 4, improved torque bar410 is made by additive manufacturing processes. Additive manufacturingtechniques may allow the design of structures to be optimized for load,strength, tuned bending resistance, and improved vibration dampingcharacteristics. In various embodiments, the geometry and configurationof torque bar 410 comprises a configuration that improves vibrationperformance (i.e., is resistant to vibration during braking), dynamicstability, among other benefits. Torque bar 410 can comprise structuresoptimized with geometric characteristics such as parallel rails 444,cross members 440 and voids 442, and/or the like to tune stiffness,reduce weight, tune bending resistance, and improve vibrationcharacteristics.

For example, torque bar 410 can comprise two rails 444. In variousembodiments, rails 444 are parallel to each other and longitudinallyoriented, and are coupled to each other by one or more cross members440.

Cross members 440 can, for example, connect one rail 444 with anotherlongitudinally-oriented rail 444. In various embodiments, cross members440 are integral to one or more rail 444. In that regard, the term“integral” in this context only may mean fabricated or manufactured as asingle, continuous component. Cross members 440 can comprise anon-rectangular configuration such as, for example, a configurationhaving a round or oval shaped cross section. In various embodiments,cross members 440 comprise a web in which multiple cross members 440 arediagonally oriented with respect to rails 444 and intersect with eachother between rails 444. In various embodiments, cross members 440 cancomprise hollow structures. In other embodiments, cross members 440 canalso comprise solid structures. In yet other embodiments, cross member440 can comprise a structure having a honeycomb style cross section. Anystructure of cross member 440 capable of coupling twolongitudinally-oriented rails 444 is within the scope of the presentdisclosure.

Torque bar 410 can further comprise one or more voids 442 locatedbetween two parallel, longitudinally-oriented rails 444. For example,one or more voids 442 can be located between two cross members 440 thatare diagonally oriented with respect to rails 444. One or more voids 442can also be located between one rail 444 and one or more cross members440. One or more voids 442 of different locations can be utilized inconjunction with one another.

In various embodiments and with reference to FIGS. 5A and 5B, torque bar410 can comprise a first cross sectional profile 550 perpendicular to alongitudinal axis 460 and a second cross sectional profile 552perpendicular to longitudinal axis 460. In various embodiments, thegeometry and configuration of torque bar 410 varies along longitudinalaxis 460, such that first cross sectional profile 550 and second crosssectional profile 552 are different from each other. For example, firstcross sectional profile 550 comprises one void 442 and two webs formedby cross members 440. Second cross sectional profile 552 islongitudinally displaced from first cross sectional profile 550 andcomprises two voids 442 and one web formed by cross members 440.Although described with reference to specific configurations, firstcross sectional profiles 550 and second cross sectional profiles 552 ofany suitable geometry are within the scope of the present disclosure.

Torque bar 410 can comprise, for example, a first metal material 450 anda second metal material 452. In various embodiments, first metalmaterial 450 can comprise a first steel or nickel base superalloy, andsecond metal material 452 can comprise a second steel or nickel basesuperalloy. Torque bar 410 can comprise a configuration in which firstmetal material 450 and second metal material 452 are combined as twodistinct materials. In other embodiments, first metal material 450 andsecond metal material 452 are combined in a uniform manner. For example,first metal material 450 and second metal material 452 can form agradient with respect to each other. However, any manner of combiningany first metal material 450 and any second metal material 452 to formtorque bar 410 is within the scope of the present disclosure. Further,torque bar 410 can comprise additional metal materials, such as a thirdmetal material. The formation of a torque bar using any number of metalmaterials is within the scope of the present disclosure.

In various embodiments and with reference to FIG. 6, a method formanufacturing a torque bar using additive manufacturing 600 can includedefining a torque bar design (step 610). For example, step 610 cancomprise utilizing two-dimensional modeling techniques to create atorque bar design having at least one of: improved dynamic stability,tuned stiffness, reduced weight, tuned bending resistance, and improvedvibration damping. For example, the torque bar design of step 610 caninclude geometric attributes such as voids 442 and web formed by crossmembers 440, as well as asymmetric features to improve stability.

In various embodiments, the torque bar design of step 610 is thenmanufactured using an additive manufacturing technique (step 620). Forexample, step 620 can comprise using a technique such as direct lasersintering to manufacture a torque bar, such as torque bar 410, havingthe same geometry and configuration as the torque bar design of step610.

In various embodiments and with reference to FIG. 7, a method formanufacturing a torque bar using additive manufacturing 700 can includecan include defining a torque bar design (step 710). Similarly to step610 of method 600, step 710 can comprise utilizing two-dimensionalmodeling techniques to create a torque bar design having at least oneof: improved dynamic stability, tuned stiffness, reduced weight, tunedbending resistance, and improved vibration damping. For example, thetorque bar design of step 710 can include geometric attributes such asvoids 442 and webs formed by cross members 440.

In various embodiments, a prototype torque bar or a prototype torque barinvestment based on the torque bar design of step 710 is formed using anadditive manufacturing process (step 720). For example, an additivemanufacturing process can be used to form a polymeric or wax prototypetorque bar based on the torque bar design of step 710. In otherembodiments, an additive manufacturing process can be used to create aprototype torque bar investment based on the torque bar design of step710. The prototype torque bar can be made from any material suitable foruse in a manufacturing process to form a torque bar.

Process 700 can further comprise a step of manufacturing a torque barbased on the torque bar design of step 710 using a casting process (step730). In various embodiments, step 730 comprises using the prototypetorque bar created by an additive manufacturing process to form a moldor investment, which is then used in a casting process to manufacture atorque bar such as torque bar 410. In other embodiments, step 730comprises using the prototype torque bar investment created by step 720in a casting process to manufacture a torque bar such as torque bar 410.In yet other embodiments, step 730 comprises using the prototype torquebar to form a torque bar using an additive manufacturing process.However, any process in which the prototype torque bar or prototypetorque bar investment created by an additive manufacturing process isused to manufacture a suitable torque bar is within the scope of thepresent disclosure.

Benefits, other advantages, and solutions to problems have beendescribed herein with regard to specific embodiments. Furthermore, theconnecting lines shown in the various figures contained herein areintended to represent exemplary functional relationships and/or physicalcouplings between the various elements. It should be noted that manyalternative or additional functional relationships or physicalconnections may be present in a practical system. However, the benefits,advantages, solutions to problems, and any elements that may cause anybenefit, advantage, or solution to occur or become more pronounced arenot to be construed as critical, required, or essential features orelements of the disclosure. The scope of the disclosure is accordinglyto be limited by nothing other than the appended claims, in whichreference to an element in the singular is not intended to mean “one andonly one” unless explicitly so stated, but rather “one or more.”Moreover, where a phrase similar to “at least one of A, B, or C” is usedin the claims, it is intended that the phrase be interpreted to meanthat A alone may be present in an embodiment, B alone may be present inan embodiment, C alone may be present in an embodiment, or that anycombination of the elements A, B and C may be present in a singleembodiment; for example, A and B, A and C, B and C, or A and B and C.Different cross-hatching is used throughout the figures to denotedifferent parts but not necessarily to denote the same or differentmaterials.

Systems, methods and apparatus are provided herein. In the detaileddescription herein, references to “one embodiment”, “an embodiment”,“various embodiments”, etc., indicate that the embodiment described mayinclude a particular feature, structure, or characteristic, but everyembodiment may not necessarily include the particular feature,structure, or characteristic. Moreover, such phrases are not necessarilyreferring to the same embodiment. Further, when a particular feature,structure, or characteristic is described in connection with anembodiment, it is submitted that it is within the knowledge of oneskilled in the art to affect such feature, structure, or characteristicin connection with other embodiments whether or not explicitlydescribed. After reading the description, it will be apparent to oneskilled in the relevant art(s) how to implement the disclosure inalternative embodiments.

Furthermore, no element, component, or method step in the presentdisclosure is intended to be dedicated to the public regardless ofwhether the element, component, or method step is explicitly recited inthe claims. No claim element herein is to be construed under theprovisions of 35 U.S.C. 112(f) unless the element is expressly recitedusing the phrase “means for.” As used herein, the terms “comprises”,“comprising”, or any other variation thereof, are intended to cover anon-exclusive inclusion, such that a process, method, article, orapparatus that comprises a list of elements does not include only thoseelements but may include other elements not expressly listed or inherentto such process, method, article, or apparatus.

What is claimed is:
 1. A method, comprising: defining a torque bardesign comprising: a torque bar body having a first rail parallel to asecond rail, the first rail and the second rail joined by a first crossmember and a second cross member, wherein the first cross member and thesecond cross member form a web defining: a first void bounded by thefirst cross member and the second cross member, the first void extendingcompletely through the torque bar body between the first rail and thesecond rail; a second void bounded by the first rail, the first crossmember and the second cross member, the second void extending completelythrough the torque bar body; and a third void bounded by the secondrail, the first cross member and the second cross member, the third voidextending completely through the torque body; a mounting hole located inthe torque bar body; and a pin extending longitudinally from the torquebar body wherein the torque bar body comprises a first perpendicularcross sectional profile that is different from a second perpendicularcross sectional profile, wherein the first perpendicular cross sectionalprofile includes the first void and the second perpendicular crosssectional profile includes the second void and the third void; andwherein the first cross member is diagonally oriented with respect tothe first rail and the second rail, and wherein the second cross memberis diagonally oriented with respect to the first rail and the secondrail, and manufacturing a torque bar based on the torque bar design. 2.The method of claim 1, wherein the torque bar comprises a first metalmaterial and a second metal material.
 3. The method of claim 1, whereinmanufacturing the torque bar comprises manufacturing the torque barusing an additive manufacturing process.
 4. The method of claim 1,wherein manufacturing the torque bar further comprises creating one of aprototype torque bar and a prototype torque bar investment based on thetorque bar design using an additive manufacturing process; and using theprototype torque bar or the prototype torque bar investment created bythe additive manufacturing process to manufacture the torque bar using acasting process.